Plant Monitoring & Performance Optimization
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Plant Monitoring & Performance Optimization
- 1. Plant Monitoring & Performance Optimization …with the experience of a leader… The new software generation for the Industry
- 2. Agenda Home Εισαγωγή Plant Vision Lot’s Description of the problem Tacking Quality Monitoring and Controlling of the Production Control FSMS Conclusions Operations Total Traceability Quality Inspection Food Safety Conclusions
- 3. The current situation Home Εισαγωγή Plant Vision Lot’s Tacking Quality Control FSMS Conclusions The absence of a system for the production process, constitutes the inspection and controlling of the production impossible.
- 4. The Problem – Lacking control of Production Processes Home Εισαγωγή “Many production companies coil from the ERP, which not only failed Plant Vision Lot’s Tacking to achieve the expected results, but had also negative implication in Quality Control the production” (AMRResearch). FSMS Conclusions “Poor Supervision into plant operations, was the biggest problem for the Director of the factory” (Forrester’s research, 2000). “The most efforts to increase the productivity in the factory, suffer from the same syndrome. The accuracy, the immediacy and the effectiveness of the production elements” (John Dyck April 25th 2002)
- 5. The Challenges “Total Traceability” Home Εισαγωγή Plant Vision Fast Response Time Lot’s Tacking Quality Minimizing inventories of Intermediate Items (WIP) Control FSMS Conclusions Immediate recognition and problem solving Documenting results of quality inspections Keeping Lot’s genealogy Analytical tracking of production related elements
- 6. The Solution “RF technology in Production” Home Εισαγωγή Plant Vision The usage of barcoded production documents and items’ Lot’s Tacking labeling allow immediate collection of actual data of Quality Control production with the use of RF technology. FSMS Conclusions The Visualizator and the Events manager support with real time information the managers’ work of controlling. Lot’s genealogy ensures “up stream” and “down stream” tracking within the plant.
- 7. Inspection and Control of Production
- 8. Basic Principles “Goods Flow Monitoring in Production” Home Εισαγωγή Plant Vision Lot’s Tacking Quality Control Materials Products FSMS Production Conclusions Production Material Materials Product s Intermediate s Intermediate Products Item Intermediate Material Items Inventory Transactions Production Production Phase Phase Cycle Count & Transactions Intermediate – Semi-finished Item Movement Semi-finished item, Stored in a production warehouse Issue Output of a production phase Receipt Item consumed in a production phase
- 9. Functions “Goods Flow Monitoring” Set-up of production specifications Home Εισαγωγή Plant Vision Lot’s Tacking Creation of production orders – soft allocation Quality Goods issue Control FSMS Materials consumption through production Conclusions Production of semi-finished and intermediate items Co-products Production Delivery to the storage warehouse Completion and closing of production orders Movements’ automation Cycle Counting of Production inventories and reallocation of differences
- 10. Functions ”Goods Flow Monitoring” Home Εισαγωγή Plant Vision Lot’s Production Issue Other Functions Process Replenishment Tacking Quality Cycle Counting Lots Pre-selection Production Issues Recording of of WH Replenishment of production inventories RPL Control FSMS WH Conclusions WIP A WIP B Production pre-print the pallet labels Ability to Re-Allocation ofwith cycleon estimated values Automated issues based count differences Replenishment the total quantities RPL Production Delivery Backflushing to production quantities for a range of days Direct issue of inventory Replenishment Materials Block – unblockwith partial Production Production Receipt Receipt Inverse backflushing of Produced Items WH Materials returns FIFO management Centralized replenishing Production Production WH Raw Issue Issue Materials Finished Production ofunallocated WIP inventories Zero stock count differences internal movement to Considering intermediate with the next phase Products Lot Mixing Production Production Direct Production Receipt in the receipt location of storage warehouse Phase A Phase B Issuing and picking issues Intermediate items for non-warehouse managed storage locations Production Delivery
- 11. One Case ”Goods Flow Monitoring” Home Εισαγωγή Plant Vision Production Lot’s Tacking Quality Control FSMS Conclusions The system is immediately updated andabout the receiptunder control The System is immediately informed the stock is still quantities. The productiondocument for expected receipts by order or on the specificdate! Printed area receives the materials needed, based by supplier & document ! and Materials are the “production warehouse” ! visualized in available for production !
- 12. One Case ”Goods Flow Monitoring” Home Εισαγωγή Plant Vision Production Lot’s € Tacking Quality Control FSMS Conclusions Material’s issuing is executed based on printed documents ! Production is continuously controlled and visualized !
- 13. One Case ”Goods Flow Monitoring” Home Εισαγωγή Plant Vision Production Lot’s € Tacking € Quality Control FSMS Conclusions The warehouse inbound is executed based on printed document of “mobile computing” delivers be applied on salesminimize the operations ! Low costtechniques can a flexible available for inbound ! effort ! Similar materials can be buck-flashed, to deliveries as well ! Products are visualized as way to handle special product’s availability. The system is immediately updated!
- 14. Special Features Home Εισαγωγή Plant Vision Characteristics of the approach Lot’s Tacking Usage of Production Warehouse to model the Production Area Usage of Intermediate Items to treat non-finished goods as Quality Control FSMS inventory controlled goods Conclusions Usage of Production Phases to record Issue and Receipt Advantages Control of Production Inventories like regular Inventories: Inventory Levels and Inventory Values Inventory Transactions (Issue, Receipt, Cycle Counting and Inventory Adjustment, Inventory Movement) Inventory Planning under the aspect of Replenishment Split of Production Activities into Phases allow the definition of Intermediate Items, that can be traced easily and thereof support the Order tracking.
- 15. Functions ”Operations Monitoring” Home Εισαγωγή Set-up of BOMs Plant Vision Lot’s Tacking Quality Control Production schedule for production orders FSMS Conclusions Initial entries – completion of the operation Interruption of the operation and reasons Recording of non-productive times Journals for the machines, workers and tools Management of available resources
- 16. Visualization - Inventory and Production Home Εισαγωγή Plant Vision Lot’s Tacking The techniques and the diagrams of the Inventory Visualization applied on production areas. Quality Control FSMS Conclusions
- 17. Event Manager Home Εισαγωγή Plant Vision Lot’s Tacking Specific parameters constitute reason for event checking, such as negative stock, extend time of delay, work Quality Control corruption etc. FSMS Conclusions Each event or the type of the event raises an action from the system, such as an SMS, which is send to one or more receivers, e-mails, messages through RF’s etc.
- 18. Elements for the Production Planning Home Εισαγωγή Plant Vision Regarding the Inventory Planning Lot’s Tacking Calculation of materials quantities, based on the production plan Availability check of the inventory before the creation of the Quality Control FSMS production order Conclusions Current, expected and allocated stocks are considered in the calculation of the available stock Keeping track of unsuitable stock and stock to be scrapped Regarding the capacity of the machines Capacity allocations and utilization in calendars Secondary production sources are controlled (mould, tools etc.)
- 19. Cost Elements Home Εισαγωγή Plant Vision Lot’s Tacking Quality The following functions are supported Control FSMS Conclusions Standard cost calculation Estimated production costing and Actual production costing
- 21. Traceability Home Tracing & Genealogy Εισαγωγή Plant Vision Lot’s Tacking Quality Control Lots FSMS Conclusions Items Orders Tracking Lots Orders Transport Bin
- 22. Lots’ Genealogy Home Εισαγωγή Plant Vision Lot’s Tacking Quality Control FSMS Conclusions
- 24. Quality Inspection Functions Quality Plans Home Εισαγωγή Plant Vision Lot’s Definition of Quality Inspections by production phase, operation, material Tacking or product Quality Control Sampling policy and frequency of measurements Inspection characteristics, methods of measure, nominal values and FSMS tolerances Conclusions Tools’ calibration Quality Inspection Documentation Printing of quality inspection notes Recording of the measurements Compliance reports Technical RF Functions Notes with printed bar code Entry of the measurement by scanning the note
- 26. The Problem… Home Εισαγωγή Plant Vision In European Union we face 7,500,000 to 105,000,000 Lot’s Tacking food poisonings from microbiological sources every year. Quality Control FSMS Conclusions The cost for the economy of the EU countries is 8,3 billion € The cost for the consumers and the medicare system is UK 1.139.264.119 £ for salmonella in 1996 UK 221.932.358 £ for salmonella for the industry in 1996 In Greece 19,6 billion yearly for salmonella Important nutrition crises Bovine Spongiform Encephalopathy (BSE) Dioxins in food chain
- 27. The Decisions … The EU “White Paper” of year 2000 Home Εισαγωγή Plant Vision The aim is to convert the European policy to an Lot’s Tacking preventive Quality Control dynamic FSMS consistent Conclusions complete tool for the consumer protection Rule 178/2002 From the production to the consumers’ table Integrated systems for tracking and tracing for the whole chain Establishment of the European Food Authority and the National Authorities Risk Analysis – Evaluation, Management, Information European Union Guide 93/43/ΕΟΚ (HACCP) compulsory from 2003 and the total traceability from 2005 special guides per sector 91/497 &498, 92/46 & 47 etc.
- 28. The Rules … Home Εισαγωγή Plant Vision From the “repressive” quality to the “preventive” Lot’s Tacking quality Quality Control FSMS Creation of the Infrastructure Conclusions Staff training (ΚΥΑ 487/21-9-2000 ΦΕΚ Β’ 1219) GMP (Good Manufacturing Practice) GHP (Good Hygiene Practice) SSOP (Sanitation Standard Operation Procedures) Other special prerequisite infrastructures Τhe H.A.C.C.P., (Prototype ELOT 1416, Guide EU 93/43) A check tool that became pressing need
- 29. The Need Home Εισαγωγή Integration of distinct systems and technological support of their management Plant Vision Lot’s Specifications (formula, quality inspections, production, maintenance, cleaning, Tacking Quality Control inspection and releasing, transportation and storage instructions) FSMS Quality Inspection (inspection results) Conclusions Total traceability (lot’s labeling and recognition, quantity – time - component) Asset management (machines, test instruments) Certificates management GMP (Good Manufacturing Practices) GHP (Good Hygenic Practices) H.A.C.C.P., decision tree and critical control points Staff training Customer’s complaints management ISO, complete management CARs Corrective and preventive actions
- 30. The Solution ”Food Safety Management System” Home Εισαγωγή ISO – Document Management Plant Vision Lot’s Tacking Controlled document’s management, archives Quality Control Corrective actions (corrective / preventive / other) FSMS SSM’s Supportive Safety Measures Customers’ complains Conclusions Internal and external audits Staff training Other SSM’s (periodic actions such as maintenance etc) HACCP functions Hazards HACCP Categories Process Steps and Procedures Food Safety Plans per item or HACCP category Hazard evaluation (Decision tree) HACCP Plans – critical control points Quality Plans and quality inspections HACCP system confirmation
- 31. Plant Vision FSMS Home Εισαγωγή Plant Vision Lot’s Tacking Quality Control FSMS Conclusions
- 32. Conclusions
- 33. Conclusions Why Mantis S.A. ? Home Εισαγωγή Plant Vision Because the accumulated experience on materials tracking and goods flow, ensures Lot’s Tacking a successful implementation for “Plant Vision” Quality Why “Plant Vision” ? Control Because the value of the immediate information for the materials’ topology and the FSMS work flow in the production is important, provided that it can avoid bottlenecks, it Conclusions can help to the normal operation of the factory and to the continuous work control Why “Visualization” ? Because information needs to be displayed in a comprehensive and immediate way to facilitate immediate reactions Why “Goods Flow Monitoring” ? Because the techniques and the technology of goods tracking within a warehouse, can be applied to the goods flow within the production process as well, resulting the complete and analytical lots traceability and the quantity supervision in the production process
- 34. Summary Home Εισαγωγή Plant Vision Why ”Plant Vision” ? Lot’s Tacking Because is the only system that delivers what was always missing Quality Control from any production management system! FSMS Conclusions Fast and immediate capturing of production data Visual and graphical presentation of materials flow Complete and analytical traceability of lots and S/N Control of production efficiency Integration with three data collection systems (PLC’s) Integration with the ERP
- 35. Information flow in an integrated multi-system environment Home Εισαγωγή Plant Vision Lot’s Tacking ERP Quality Control Financial Module FSMS Commercial Module Conclusions MES WMS Inventory Management Warehouse Management Production Management Transportation Management Information support of the ERP and execution link with WMS …
- 36. When WMS and MES become one … Home Εισαγωγή Plant Vision ERP Lot’s Tacking Quality Control Financial Module FSMS Commercial Module Conclusions MES WMS Inventory Management Warehouse Management Production Management Transportation Management Our scope is the “intra” and “inter-plant” Supply Chain Management Solution!
- 37. …with the experience of a leader… Thank you for your attention!